Wood fired boiler

ABSTRACT

A bio-mass fueled boiler operating at delivered efficiencies in excess of 90%. Pre-heated, pressurized primary combustion air is supplied to a primary burn chamber via horizontal and vertical orifice containing conduits. Exhaust gases are directed past a reflective secondary burner supplying pre-heated, pressurized secondary combustion air into a secondary burn/ash collection chamber. Exhaust gases are directed from the secondary burn chamber via exhaust conduits having axial and cross-sectional shapes and wall geometries that promote internal turbulence and heat transfer. One or more gas/oil fired burners are fitted to or between the primary and secondary combustion chambers. Several operating modes are provided via associated blowers, air baffles, liquid and gas fuel conduits, pumps and sundry stove sensors and servos coupled to microprocessor control circuitry.

RELATED APPLICATION DATA

This is a non-provisional application of provisional application Ser.No. 60/906,897, filed Mar. 13, 2007.

BACKGROUND OF THE INVENTION

The present invention relates to biomass fueled stoves and boilers and,in particular, to a high efficiency wood or other biomass fueledstove/boiler wherein multiple combustion chambers and exhaust gasconduits are collectively surrounded by a liquid thermal transferchamber to capture released heat energy and wherein exhaust gases torepetitively subjected to turbulent, pre-heated, pressurized combustionair to burn off hydrocarbons and other pollutants.

A wide variety of low-pressure wood and alternative biomass fuel (e.g.wood, coal, corn and other seeds, chips, pellets, crop waste etc.)stoves and boilers have been developed for residential and commercialuse. Many of the boiler assemblies are constructed as stand-alone,weatherproof assemblies that are remotely located adjacent a heatedbuilding. Low pressure liquid supply lines are conducted from the boilerto an insulated, liquid distribution system at the heated facility. Theheated facility is thereby isolated from any fire danger and exhaustgases are dispersed to the environment.

Many existing wood fueled stoves and boilers are relatively inefficientand exhaust smoke and flue gases that contain high concentrations ofhydrocarbons that are hazardous to the environment. Efforts increasinglyhave been extended to improve stove/boiler efficiencies to increasethermal capture and reduce carbon emissions.

The present invention and novel biomass fueled stove/boiler wasdeveloped to provide a stove/boiler that is compatible with wood, coat,pellets and other biomass materials and is capable of burning theorganic biomass fuel materials at efficiencies in excess of 90% withsubstantially reduced hydrocarbon emissions. The stove/boiler includesrefractory lined burn chambers and a surrounding liquid thermal transferchamber. The thermal transfer chamber and other heated surfaces arecovered with sprayed urethane foam insulation to assure optimal heattransfer.

Preheated, pressurized combustion air is supplied to a primary burnchamber via surrounding horizontal and vertical orifice containingconduits. Exhaust gases are substantially directed via positive ornegative fan directed pressurization into a lower, secondary burn/ashcollection chamber via a secondary burner supplied with preheated,pressurized secondary combustion air. The secondary burner directspreheated pressurized combustion air into a shaped combustion space toproduce turbulence and enhance combustion of hydrocarbons andpollutants.

The secondary exhaust gases are directed from the secondary burn/ashchamber via several fluted, fire or exhaust tubes that extend at acuteangles through the liquid thermal transfer chamber to a further heatedmixing chamber before being exhausted from an insulated stove flue. Thewall geometry and cross-sectional shape of the fire tubes promoteinternal turbulence and heat transfer. The tubes can be straight or caninclude appropriate bends. The shaping and angular extension of theexhaust tubes promotes optimal heat energy collection, hydrocarboncombustion and carbon ash collection.

One or more tertiary fuel burners (e.g. oil or gas (natural or propane))can be fitted to the primary burn chamber, between the primary andsecondary burn chambers or at the secondary burn chamber. The tertiaryburners can sustain exhaust gas combustion, facilitate cold starts oroperate to adjust for changing fuel supply costs and availability.

An associated stove controller operates and/or responds to a combustionair source, airflow baffles, liquid supply and return pumps, sensors,switches and servos in conjunction with sundry operating sensors toaccommodate several operating modes. The sensors monitor relevantoperating parameters to optimize safety and burner efficiency andminimize back drafts.

SUMMARY OF THE INVENTION

It is a primary object of the invention to provide a high efficiencybiomass fueled heating appliance (e.g. wood fueled boiler or stove).

It is further object of the invention to provide a boiler or stovewherein turbulent, pressurized, pre-heated combustion air is injectedfrom orifices displaced horizontally and vertically about a primary burnchamber.

It is further object of the invention to provide a boiler or stovewherein exhaust gases are exposed to turbulent, pressurized, pre-heatedsecondary combustion air at a secondary burner and secondary burnchamber and directed to a heated mixing and exhaust chamber.

It is further object of the invention to provide a boiler or stovewherein exhaust gases are directed past a secondary burner having shapedsurfaces and orifices from which pre-heated, pressurized secondarycombustion air is directed to induce reflections and produce turbulentcombustion in a secondary burn chamber.

It is further object of the invention to provide a boiler or stovewherein fan directed positive or negative pressurized primary andsecondary air flow is created to direct and expose exhaust gases topre-heated, turbulent, pressurized primary and secondary combustion air.

It is further object of the invention to provide a boiler or stovewherein a secondary burner directs pre-heated, pressurized secondarycombustion air in a reflective space to turbulently mix with and promoteexhaust gas combustion.

It is further object of the invention to provide a boiler or stovewherein exhaust gases are directed via angularly aligned exhaust tubeshaving wall surfaces shaped and directed to produce internal turbulenceand that extend at acute angles between internal burn and exhaustchambers to an external flue.

It is further object of the invention to provide a boiler or stoveincluding one or more alternative fuel fired burners to facilitate thereduction of hydrocarbon emissions and/or cold startups and/or adjustoperation to fuel costs and availability.

It is further object of the invention to provide a boiler or stoveincluding baffles and air control assemblies to restrict back drafts.

The foregoing objects, advantages and distinctions of the invention areobtained in a presently preferred biomass fueled boiler or stoveassembly described below. The boiler/stove provides turbulent,pre-heated, pressurized primary and secondary combustion air to combusta wide variety of biomass mass fuels with high efficiency from optimallylocated primary and secondary chambers. An insulated, liquid thermaltransfer chamber surrounds the primary and secondary burn chambers andcaptures released heat energy.

The boiler supplies primary combustion air via a injection assembly.Positively pressurized air is admitted to the fire box via horizontaland vertical orifice containing conduits. Exhaust gases are directed viaa secondary pressurized burner into a lower, secondary burn/ashcollection chamber.

Preheated, pressurized primary combustion air is directed fromhorizontally and vertically directed outlets at the primary burnchamber. The horizontal conduits are arranged below the vertical centerof the primary burn chamber. A substantial portion of the exhaust gasesare directed from the primary burn chamber into a lower, secondaryburn/ash chamber. Pre-heated, pressurized air is directed from secondaryburner orifices to create a turbulent flame front and exhaust gastemperatures on the order of 1220 to 1500° F. to burn the emissions.Combustion of the exhaust gases and unburned hydrocarbons continues inthe secondary burn chamber which also collects ash and solid matter. Thesecondary combustion air is directed from orifices at a secondary burnerassembly constructed to produce reflections and turbulent air flow.

The secondary exhaust gases are directed via several fluted fire orexhaust tubes that extend from the secondary chamber through thesurrounding insulated thermal transfer chamber. Shaped heat transfersurfaces defined by fluting and convolutions at the fire tubes produceinternal turbulence, enhance the heat transfer surface to the liquidthermal transfer media, and maintain exhaust gas temperatures tofacilitate optimal hydrocarbon combustion.

The wall geometry and cross-sectional shape of the fire or exhaust tubesare selected to promote internal turbulence and heat transfer withoutrequiring a discrete turbulator assembly. The walls can be configured ina variety of shapes and forms that promote turbulence (e.g. withparallelogram, square, star or other grooves, projections or fluting,V-shaped edges or corners when viewed in cross section) versus round orsmooth cross-sectional shapes. The fire tubes can also be straight orinclude appropriate convolutions, bends, twists and/or turns.

The fire tubes preferably project at an acute angle in the range of 45to 80 degrees versus conventional fire tubes that typically layhorizontal and/or may wind in a horizontal serpentine path. The angulardisplacement of the present fire/exhaust tubes facilitates carbonremoval from the tubes. That is, gravity directs ash and carbon fallingfrom the tubes back into the secondary burn/ ash chamber where thecarbonized ash and solids from the primary burn chamber are continuallysubjected to secondary combustion.

A tertiary burner can be fitted to the primary burn chamber tofacilitate cold starts and/or provide for boiler operation with asecondary fuel (e.g. gas—natural or propane, oil or other petrochemicalfuels). A second gas fired burner and pressurized combustion air supplycan also be provided at the secondary burn/ash chamber. The tertiary gasfired burner(s) sustains combustion of the exhaust gases during startupand low temperature stove conditions.

Associated stove controls, servos, air baffles and the like supplyturbulent, preheated, pressurized combustion air to the primary andsecondary burn chambers. Air flow is also controlled to minimize backdrafts with the opening of either the primary or secondary burn chamberdoors.

An exhaust manifold is coupled to the primary burner and the fire tubesfrom the secondary burn chamber to control exhaust gas flow to asolenoid controlled damper at the primary flue stack fitted to the backof the stove enclosure. The liquid thermal transfer chamber and anysurfaces exposed to the flow of the liquid thermal transfer media areinsulated with heat resistant foam.

Rear compartments at the stove enclosure contain liquid supply andreturn fittings, pump(s), fan(s) and sundry stove sensors, servos,baffles and other controls. Appropriate sensors are provided and coupledto the control circuitry and a microprocessor controller to provide forseveral operating modes. The sensors and switches monitor severaldifferent operating parameters including stack temperature, watertemperature, flame conditions, oxygen levels, and door conditions.

Still other objects, advantages, distinctions, constructions andcombinations of individual features of the invention will become moreapparent from the following description with respect to the appendeddrawings. The description to each combination should therefore not beliterally construed in limitation of the invention. Rather, theinvention should be interpreted within the broad scope of the furtherappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures disclose presently preferred constructions of theinvention. Similar components and assemblies are referred to in thevarious drawings with similar alphanumeric reference characters andcallouts.

FIG. 1 is a perspective drawing showing external views to the front,right side and top of the boiler/stove.

FIG. 2 is a perspective drawing showing the boiler/stove in partialcutaway to expose the primary and secondary burn chambers and exhaustfire tubes.

FIG. 3 is a plan view to the rear wall of the boiler/stove.

FIG. 4 is a perspective drawing showing with the primary door open andexposing the primary burn chamber and upper region of the secondaryburner.

FIG. 5 is a plan view to the front wall of the boiler/stove with theprimary door open and exposing the upper region of the primary burnchamber.

FIG. 6 is a perspective drawing showing the boiler/stove in partialcutaway to expose the liquid thermal transfer chamber, primary burnchamber without the refractory lining, the secondary burn chamber, andthe exhaust fire tubes.

FIG. 7 is a plan view to the front of the boiler/stove with portions ofthe interior structure shown in dashed line.

FIG. 8 is a perspective drawing showing the right side of theboiler/stove with several of the thermal transfer chamber and primaryand secondary burn chamber walls removed.

FIG. 9 is a plan view to the right side of the boiler/stove withportions of the interior structure shown in dashed line.

FIG. 10 is a perspective drawing showing the rear and right side viewsof the boiler/stove with several of the thermal transfer chamber and airsupply chamber walls removed.

FIG. 11 is a plan view to the rear of the boiler/stove with the rearthermal transfer chamber wall removed and covers to the air supply andexhaust chambers removed.

FIG. 12 is a plan view to the top of the boiler/stove with portions ofthe underlying interior structure shown in dashed line.

FIG. 13 is a perspective drawing showing the secondary burner assemblyand wherein internal baffling is shown in dashed line.

FIG. 14 is a right side plan view to the secondary burner assembly ofFIG. 13 and wherein internal baffling is shown in dashed line.

FIG. 15 is a top plan view to the secondary burner assembly of FIG. 13and wherein internal baffling is shown in dashed line.

FIG. 16 is a perspective drawing showing a first alternative secondaryburner assembly and wherein internal baffling is shown in dashed line.

FIG. 17 is a top plan view to the first alternative secondary burnerassembly of FIG. 16 with the top wall removed.

FIG. 18 is a perspective drawing showing a second alternative secondaryburner assembly and wherein internal baffling is shown in dashed line.

FIG. 19 is a top plan view to the second alternative secondary burnerassembly of FIG. 18 with the front wall removed.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 through 5, several views are shown to the generalexternal and internal construction of the biomass fueled stove andboiler assembly 2 of the invention. The boiler 2 is compatible withwood, coal, manufactured pellets, grains, and waste agriculturalmaterials, among a variety of combustible biomass materials. The boiler2 provides a formed steel enclosure 4 having a front door 6, an ashremoval door 8 and a side-mount operational controller panel 10.

The door 6 is constructed to provide an airtight fit with an enclosedprimary burn chamber 12. The primary burn chamber 12, ash chamber andassociated exhaust gas flow paths are surrounded by an insulated liquidthermal transfer chamber 14. An upright, insulated exhaust gas flue 16is supported to the rear surface of the boiler 2.

The primary burn chamber 12 provides a floor 18 and side walls 20constructed or covered with bricks 22 formed from suitable refractorymaterials capable of withstanding normal operating temperatures andconditions. Approximately centered in the floor 18 is a port or opening24 containing several laterally displaced refractory baffles 26 thatopen to an underlying secondary burner 28 and lower lying secondary burnchamber and ash collection chamber 30. The assembly 28 is looselyreferred to as a “burner” for convenience only since it conductssecondary combustion air and does not operate as a fueled burner.

Internal air pressures induce combustion exhaust gases to substantiallyflow into the secondary burner 28. A fan assisted, positivelypressurized boiler 2 is presently provided, although a negativelypressurized boiler 2 could also be constructed. A portion of thecombustion exhaust gases and smoke are drawn off the top of the primaryburn chamber 12 where the gases are directed to the flue 6 via a primaryexhaust conduit 32, reference FIG. 5. Gases flow through the conduit 32principally when the door(s) 6 and/or 8 are opened. The relativepressures within the primary and secondary burn chambers 12 and 30adjust with the door opening to direct the gases through the conduit 32instead of as a back draft at either of the door(s) 6 and/or 8. The heatand turbulent air flow within the primary burn chamber 12 assures thathydrocarbons contained in the gases at the top of the burn chamber 12are optimally incinerated prior to being directed via the port 32 to anexhaust gas manifold or mixing chamber 34 mounted to the rear wall ofthe burn chamber 12.

Baffles can be included at the conduit 32 to further facilitate backdraft control. Similarly and although not depicted, additionalprovisions can be made at the secondary burn chamber 30 and/or door 8and/or boiler controls to prevent back drafts from the secondary burnchamber 30 upon opening the ash door 8.

During normal operation, the bulk of the exhaust gases are directeddownward past the secondary burner 28 and into the secondary burn andash chamber 30. Ash or solid waste combustion byproducts are removedfrom the ash chamber 30 via the door 8. The exhaust gases are directedfrom the secondary burn chamber 30 via several fluted and/or convolutedfire or exhaust tubes 36. The bores or inner diameters of the tubes 36are shown in cutaway at FIG. 2. The tubes 36 extend in side-by-sideparallel relation to each other at an acute angle from the secondaryburn chamber 30 to the exhaust gas manifold or mixing chamber 34.

The exhaust gases from the primary and secondary burn chambers 12 and 30are collected at the manifold 34 and directed past a controlled baffleor damper 38 to the flue 6. A laterally directed linkage arm assembly 40is mounted to pivot and control the damper 38. The exhaust gas volume iscontrolled in relation to monitored operating temperatures to provideoptimum burning of hydrocarbons and other pollutant materials. Deliveredoperating efficiencies at industry “high heating value” (HHV) and “lowheating value (LHV) ratings have been obtained in the ranges of 60% to80% HHV and 65% to 90% LHV. Collectively, general delivered efficiencieshave been measured in the range of 60% to 91% for the stovelboiler 2.

FIGS. 6 through 12 depict additional details to the construction of theexhaust manifold 34 and several other air control and tertiary burnerassemblies described below. Removable panels 42, 44 and 46 are mountedto the framework of the housing 4 at a rear wall 48 and permit access tothe various burners, fans, pumps, baffles, servos, plumbing fittings andthe like used to operate the stove/boiler 2. A further cover 50 permitsaccess to the primary flue 6 for inspection and cleaning.

The stove/boiler 2 is designed to operate with biomass fuels, however, atertiary, gas or oil fired burner 52, such as disclosed at U.S. Pat. No.6,718,889, is fitted to a conduit 54 at a rear wall of the primary burnchamber 12. The tertiary burner 52 is principally operated during coldstarts until the stove 2 reaches operating temperatures. Alternatively,the burner 52 can be used as a primary heat source when wood or otherbiomass materials are unavailable or too costly or during periods whenoperating personnel aren't available to tend the stove/boiler 2.

The 80% plus operating efficiencies of the stove/boiler 2 are obtainedin part by injecting pressurized air into the primary and secondary burnchambers 12 and 30 and at the exhaust fire tubes 36. Preheated,pressurized combustion air is injected into the primary burn chamber 12via a hollow conduit assembly 60 that substantially circumscribes theprimary burn chamber 12 and through which the conduit 54 passes. Theassembly 60 includes horizontal segments 62 that circumscribe the rearand side walls of the primary burn chamber 12. The horizontal segments62 are located at or below the vertical height of the primary burnchamber 12 to maintain the combustion air near the primary combustionzone for the particular combustion material. Primary combustiontypically occurs in the lower third of a pile of combustible material ornear the ash pile.

Vertical segments 64 extend from the ends of the segments 62 and projectparallel to the sides of the door 6. The assembly 60 is thus locatedslightly above the refractory floor 18 and below the midway point of theprimary burn chamber 12 to promote combustion.

Orifices 66 displaced along the segments 62 and 64 dispense pressurizedcombustion air conducted through the conduit assembly 60 into theprimary burn chamber 12. The pressurized combustion air mixes with thecombustion gases and smoke to produce turbulence and enhance the burningof hydrocarbons. The size and location of the orifices 66 are selectedto optimize fuel combustion within the chamber 12. The primarycombustion air admitted to the stove/boiler 2 exhibits a nominalpositive pressure in the range of 0.1 to 1 inch of water column (WC)within the primary burn chamber 12. The positive pressure is obtainedwith primary and secondary combustion air fan assist assembliesdiscussed below. It is to be appreciated negatively pressurizedstove/boiler 2 could be constructed to draw primary and secondarycombustion air and exhaust gases through the assembly 2 with fan orother airflow assist assemblies.

The pressurized air is supplied from an air manifold or plenum 66mounted to the rear wall of the thermal transfer chamber 14. The chamber14 is fed by a fan 68, reference FIGS. 8 through 11. Air is directedfrom the plenum 66 into a conduit 70 that extends to the primarycombustion air conduit assembly 60. An intermediate solenoid operatedbaffle 72 controls air flow into the conduit 70. Another conduit 74 andsolenoid controlled baffle 72 direct pressurized combustion air into thesecondary burner 28. A further conduit 76 and solenoid controlled baffle72 direct pressurized combustion air into the secondary burn chamber 30.The conduit 76 can also cooperate with a gas or liquid fired burner(e.g. propane or natural gas or oil) similar to the burner 52 to supportand enhance combustion in the secondary burn chamber 30. Microprocessorcontrol circuitry at the controller 10 determines appropriate timingsignals to control the on/off duty cycling of the baffles 72 and gas/oilfired burners 52.

Turning attention to FIGS. 4, 6, 8, and 12 through 15, the ash port 24is located at the approximate center of the refractory floor 18. Thebaffles 26 segregate the port 24 to receive and direct combustion gasesand smoke into the secondary burn chamber 30. Upon pressurizing theprimary chamber 12 via the primary combustion air conduit assembly 60, asubstantial portion of the combustion exhaust gases and smoke aredirected past the secondary burner 28 and into the secondary burnchamber 30. The exhaust gases pass through an arcuate vertical channel80 defined by an arcuate (e.g. semi-circular) front wall 82 of thesecondary burner 28 and a rear wall 84 of the secondary burn chamber 30.

Pressurized and preheated secondary combustion air is conducted viaconduit 74 to the side wall of the secondary burner 28 and into a cavity81 behind front wall 82. A portion of the pressurized air is divertedinto right and left wing chambers 83 and 85 that depend from the sidesof the burner 28 into the secondary burn chamber 30. Internal baffles 86at the wing chambers 83 and 85 divert a portion of the secondarycombustion air into the depending portions of the wing chambers 83 and85.

The disruption and partial bleeding of air flow into the wing chambers83 and 85 induces turbulence in the cavity 81 and wing chambers 83 and85. The turbulence and re-direction of air produces a delay in the airflow before the air is ejected from orifices 88 arranged over thearcuate burner wall 82. The delay facilitates the preheating of thesecondary combustion air from the conduit 74 in the cavity 81 beforebeing ejected into the channel 80 and secondary burn chamber 30,reference FIGS. 13, 14 and 15. Thermal energy is also transferred to thedepending portions of the wing chambers 83 and 85 that extend into thesecondary burn chamber 30 to maintain combustion of hydro carbons in theexhaust gases in the secondary burn chamber 30.

The secondary combustion air directed from the orifices 88 strikes andreflects the exhaust gases in the channel 80 between the walls 82 and84. The resulting mixing and turbulent flow optimizes the ignition andcombustion of hydrocarbons and other combustibles in the exhaust gasesthat flow through the channel 80 and into the secondary burn/ash chamber30.

FIGS. 16 and 17 depict a first alternative secondary burner 90. Theburner 90 provides an arcuate front wall 92 that also directs preheatedpressurized secondary combustion air into exhaust gases directed intothe channel 80 and secondary burn chamber 30. The wall 92 providesseveral panels 94 that each contain an orifice 96. The panels 94 arearranged to form a semi-circular arc of suitable radius. Secondarycombustion air admitted into an interior cavity 95 of the burner 90 viathe conduit 74 is delayed by baffles 96 and 98 with a consequent heatingof the air before being ejected from the orifices 96.

The mixing of the secondary combustion air with the exhaust gases in thechannel 80 again produces reflections and consequent turbulent flowbetween the faces of the panels 94 and the rear wall 82 of the burn/ashchamber 30. Like the burner 28, the burner 90 thus produces turbulentflow that optimizes the combustion of hydrocarbons and othercombustibles in the gases.

FIGS. 18 and 19 depict a second alternative secondary burner 100. Theburner 100 provides a semi-circular, corrugated front wall 102 that alsodirects preheated pressurized secondary combustion air into exhaustgases directed into the channel 80 into the secondary burn chamber 30.The wall 102 provides several grooved recesses 94 defined by opposedwall panels 106 that each contain an orifice 108. The panels 106generally project at 90° to each other. Secondary combustion airadmitted to the interior of the burner 100 is delayed by a baffle 110before being ejected from the orifices 108. The mixing of the combustionair with the exhaust gases passing through the channel 80 producesreflections between the rear wall 80 and between adjacent faces of thepanels 102. Like the secondary burners 28 and 90, the secondary burner100 produces turbulent flow that optimizes the combustion ofhydrocarbons and other combustibles in the exhaust gases admitted to thesecondary burn/ash chamber 30. It is to be appreciated still othersecondary burner configurations can be constructed to induce turbulencein the exhaust gases.

Combustion continues in the secondary burn/ash chamber 30 uponsubjecting the exhaust gases to additional pressurized and heated airsupplied from the conduit 76. A fuel fired burner (e.g. propane ornatural gas or oil) like the burner 52 can be fitted to the conduit 76to sustain and enhance combustion in the secondary burn chamber 30. Thesecondary burn/ash chamber 30 is also lined with refractory materials tomaintain secondary burn temperatures.

As combustion of the exhaust gases continues in the secondary burnchamber 30, the gases are directed to the several fluted fire or exhausttubes 36. The tubes 36 extend at an acute angle between the secondaryburn chamber 30 and the exhaust manifold 34 mounted to rear wall of thethermal transfer chamber 14. The tubes 36 are spaced apart from andextend parallel to each other. The tubes 36 extend through the thermaltransfer chamber 14 and the liquid flows around each tube 36. The numberand spacing between the tubes 36 is selected to facilitate heat transferfrom the heated exhaust gases to the liquid media contained in thethermal transfer chamber 14. The tubes 36 project from the secondaryburn chamber 30 at an acute angle in the range of 40 to 70 degrees.

The walls of the tubes 36 are shaped and formed to delay and promoteturbulent flow through the fire tubes 36. The prolonged, turbulent flowenhances the burning of hydrocarbons contained in the exhaust gases,heat transfer and ultimately enhances efficiency of the stove/boiler 2.

The walls of the exhaust/fire tubes 36 presently define bores thatexhibit a parallelogram shaped, transverse cross-sectional profile, seethe cutaway of the exhaust/fire tubes 36 at FIG. 2 and the exposed endsat FIGS. 7, 8, 11 and 12. The wall geometry and transverse andlongitudinal cross-sectional shapes of the exhaust/fire tubes 36 can bevaried as desired to promote internal turbulence and heat transferwithout requiring the mounting of a discrete turbulator assembly alongthe path of the exhaust gases. For example, the walls can be configuredto define in a variety of cross-sectional bore shapes and forms such asthe depicted parallelogram shape or with square, star or other straightor curved wall section shapes. The tube walls may also be formed withgrooves, fluting, projections, obstructions and/or V-shaped edges orcorners. The wall surfaces can also be varied and/or interrupted withchanged shapes or bends along their lengths. The fire tubes 36 can beformed straight as depicted or can include appropriate bends, twistsand/or turns. Any ultimate tube shape and/or combination is desirablyconstructed to promote turbulence in the exhaust gases versus smoothcross-sectional shapes.

The acute, angular alignment of the exhaust or fire tubes 36 is arrangedto direct carbon deposits that flake from the walls of the exhaust tubes36 back into the secondary burn/ash chamber 30. Carbon deposits in thetubes 36 can also be manually cleaned upon opening the access panel 42at the exhaust manifold 34. As the tubes 36 and carbon deposits arescraped or brushed from the interior walls of the tubes 36, the depositsfall into the ash chamber 30 and are removed via the door 8. Thecontinual exposure of the combustible solid materials in the secondaryburn chamber 30 and placement of the secondary burn chamber 30 in thethermal transfer chamber 14, assures that essentially all combustiblematerials are burned and the released heat energy is captured.

As mentioned, the space behind the rear covers 44 and 46 and in front ofthe insulation that covers the rear wall of the thermal transfer chamber14 contains liquid supply and return fittings, liquid conduits 106, aliquid pump, fan blower 68, baffles 72, gas/oil burners 52, flamesensors, thermostat sensors, and sundry other stove servos, sensors andcontrols. The control devices communicate with programmed microprocessorcircuitry at the controller 10 and variously supply and receive controlsignals. The sensors and switches monitor among different operatingparameters, stack temperature, water temperature, flame conditions,oxygen levels, and door conditions.

The microprocessor is programmed to control several general modes ofoperation. A “cold start” mode operates to supply gas to the tertiarygas/oil burner(s) 52 to provide heat to ignite the biomass pile. Thetertiary burner(s) 52 are subsequently operated to optimize combustionefficiencies or during a “backup” mode if the stove temperature fallsdue to fuel depletion.

Once ignited and during a “run mode”, the biomass burns and thestove/boiler 2 is controlled to maintain a thermostatically settemperature and appropriately direct combustion air flow via the blower68 and baffles 72. During the run mode the duty cycle or on/off times ofthe baffles 72 are appropriately controlled to maintain optimal burnconditions.

While the invention is shown and described with respect to a presentlypreferred stove/boiler assembly and several considered improvements,modifications and/or alternatives thereto, still other assemblies andarrangements may be suggested to those skilled in the art. It is also tobe appreciated that the foregoing singular and/or combinational featuresof the stove/boiler can be arranged in different combinations. Theforegoing description should therefore be construed to include all thoseembodiments within the spirit and scope of the following claims.

1. A boiler comprising: a) an enclosure having a door and defining aprimary burn chamber adapted to receive a combustible biomass materialand coupled to an exhaust gas port open to the environment; b) aplurality of conduits arrayed inside said primary burn chamber andhaving orifices exposed to the interior of said primary burn chamber; c)a secondary burn chamber coupled to receive exhaust gases from saidprimary burn chamber; d) a secondary combustion air conduit mountedbetween said primary and secondary burn chambers having an arcuatesurface aligned opposite walls of the secondary burn chamber, containinga plurality of orifices and including a cavity space containing bafflesfor diverting and delaying airflow through said cavity space and saidorifices; e) a plurality of tubular exhaust gas conduits coupledintermediate said secondary burn chamber and said exhaust gas port andhaving bores formed to produce turbulence in exhaust gases conductedtherethrough; f) a source of combustion air coupled to said plurality ofconduits at said primary burn chamber and the cavity space of saidsecondary combustion air conduit and controlled to 1) direct air throughthe conduit orifices to positively pressurize the primary burn chamberand direct combustion exhaust gases containing hydrocarbons past saidsecondary combustion air conduit and 2) direct air from the secondarycombustion air conduit orifices to produce a turbulent and air andexhaust gas mixture and combustion of the exhaust gases prior toentering the secondary burn chamber; g) a heat exchanger having anenclosure surrounding said primary and secondary burn chambers, saidsecondary combustion air conduit and said plurality of exhaust gasconduits and containing a liquid heat exchange media and means forcirculating said liquid media through said enclosure; and h) means forcontrolling the flow of exhaust gases from said primary burn chamber andsecondary burn chambers and exhaust conduits and through said exhaustgas port.
 2. A boiler as set forth in claim 1 wherein said secondaryburn chamber comprises an ash collection chamber surrounded by said heatexchange enclosure, wherein said secondary burner underlies ash portsmounted beneath a pile of said biomass materials, and wherein a portionof the cavity space of said secondary combustion air conduit extendsinto a lower lying portion of said ash chamber such that the secondarycombustion air is preheated before being injected by the orifices of thesecondary burner into the stream of exhaust gases.
 3. A boiler as setforth in claim 1 wherein the orifices of said secondary combustion airconduit are exposed through a corrugated arcuate surface alignedopposite walls of the secondary burn chamber to reflect the pressurizedcombustion air and exhaust gases injected into to the secondarycombustion air conduit between the corrugations and secondary burnchamber walls to induce turbulence into the mixture flow of exhaustgases and combustion air prior to entering the secondary burn chamber.4. A boiler as set forth in claim 1 wherein a first portion of theconduits in said primary burner are horizontally arrayed about thecircumferential walls of said primary burner adjacent to an the upperregion of biomass fuel materials burned in said primary burn chamber andwherein a second portion of the conduits extend vertically parallel tolateral sides of a door opening to produce turbulence in the releasedexhaust gases and direct the exhaust gases downward to said secondaryburn chamber when the door is closed and direct the exhaust gases tosaid exhaust port when said door is open.
 5. A boiler as set forth inclaim 1 including a burner coupled to said source of combustion air andfueled by a gas or liquid fuel and mounted to said primary burn chamberto initiate combustion of said biomass materials and exhaust gashydrocarbons within said primary burn chamber or independently heat theprimary burn chamber and microprocessor means responsive to a pluralityof temperature sensors for operating said burner.
 6. A boiler as setforth in claim 1 including a burner coupled to said source of combustionair and fueled by a gas or liquid fuel and mounted to said secondaryburn chamber to maintain secondary combustion of hydrocarbons in theexhaust gas within said secondary burn chamber and microprocessor meansresponsive to a plurality of temperature sensors for operating saidburner.
 7. A boiler as set forth in claim 1 including an exhaust gasmanifold coupled to said primary burn chamber, to said plurality ofexhaust gas conduits, and to said exhaust gas port.
 8. A boiler as setforth in claim 7 wherein said exhaust gas conduits extend externally atan acute angle from said secondary burn chamber to said exhaust gasmanifold.
 9. A boiler as set forth in claim 8 wherein the bores of saidexhaust gas conduits exhibit a rectilinear cross sectional profileformed to promote turbulent flow of exhaust gases through said exhaustgas conduits.
 10. A boiler as set forth in claim 9 wherein said exhaustgas manifold includes a baffle coupled to control the flow ofhydrocarbon depleted exhaust gases through said exhaust gas port to theenvironment.
 11. A boiler comprising: a) an enclosure having a door anddefining a primary burn chamber adapted to receive a combustible biomassfuel and coupled to an exhaust gas port open to the environment; b) aplurality of conduits arrayed inside said primary burn chamber andhaving orifices exposed to the interior of said primary burn chamber; c)a secondary burn chamber coupled to receive exhaust gases from saidprimary burn chamber, wherein said secondary burn chamber comprises anash collection chamber; d) a secondary combustion air conduit coupledintermediate said primary burn chamber and said secondary burn chamberand having a plurality of orifices, wherein said secondary combustionair conduit includes a cavity space opening to said orifices andcontaining baffles for diverting and delaying airflow through saidcavity space to preheat the airflow, and wherein a portion of the cavityspace of said secondary combustion air conduit extends into a lowerlying ash chamber; e) a plurality of tubular exhaust gas conduitscoupled intermediate said secondary burn chamber and to said exhaust gasport and having bores formed to produce turbulence in exhaust gasesconducted therethrough; f) a source of combustion air coupled to saidplurality of conduits at said primary burn chamber and to said secondaryburner and controlled to 1) direct air through the conduit orifices topressurize the primary burn chamber and direct combustion exhaust gasescontaining hydrocarbons past said secondary combustion air conduit andinto said secondary burn chamber and 2) direct preheated air from thesecondary combustion air conduit orifices to turbulently mix with thepassing exhaust gases and induce further combustion of hydrocarbons inthe exhaust gases; g) a heat exchanger having an enclosure surroundingsaid primary and secondary burn chambers, said secondary combustion airconduit, and said plurality of exhaust gas conduits and containing aliquid heat exchange media and means for circulating said liquid mediathrough said enclosure; and h) means for controlling the flow of exhaustgases through said primary burn chamber, said secondary burn chamber andsaid exhaust gas conduits to said exhaust gas port.
 12. A boiler as setforth in claim 11 wherein a first portion of the conduits in saidprimary burn chamber are horizontally arrayed about circumferentialwalls of said primary burner and wherein a second portion of conduitsextend vertically parallel to lateral sides of a door opening to produceturbulence in the released exhaust gases and direct the exhaust gasesdownward to said secondary burn chamber when the door is closed anddirect the exhaust gases to said exhaust port when said door is open.13. A boiler as set forth in claim 12 including a burner coupled to saidsource of combustion air and fueled by a gas or liquid fuel and mountedto said primary burn chamber to initiate combustion of said biomass fueland exhaust gas hydrocarbons within said primary burn chamber orindependently heat the primary burn chamber and microprocessor meansresponsive to a plurality of temperature sensors for operating saidburner.
 14. A boiler as set forth in claim 12 including a burner coupledto said source of combustion air and fueled by a gas or liquid fuel andmounted to said secondary burn chamber to maintain secondary combustionof hydrocarbons in the exhaust gas within said secondary burn chamberand microprocessor means responsive to a plurality of temperaturesensors for operating said burner.
 15. A boiler as set forth in claim 12including an exhaust gas manifold coupled to said primary burn chamber,to said plurality of exhaust gas conduits and to said exhaust gas port.16. A boiler as set forth in claim 15 wherein said exhaust gas conduitsextend at an acute angle from said secondary burn chamber to saidexhaust gas manifold and wherein the bores of said exhaust gas conduitsexhibit a rectilinear cross sectional profile to promote turbulent flowof exhaust gases through said exhaust gas conduits.
 17. A boilercomprising: a) an enclosure having a door defining a primary burnchamber adapted to receive a wood fuel material and coupled to anexhaust gas port open to the environment; b) a plurality of conduitsarrayed inside said primary burn chamber and having orifices exposed tothe interior of said primary burn chamber, wherein a first portion ofthe conduits in said primary burn chamber are horizontally arrayed aboutcircumferential walls of said primary burn chamber and wherein a secondportion of the conduits extend vertically; c) a secondary burn chambermounted below the primary burn chamber and coupled to receive exhaustgases and ash from said primary burn, chamber; d) a secondary combustionair conduit coupled intermediate said primary burn chamber and saidsecondary burn chamber and having an arcuate surface containing aplurality of orifices mounted opposite a wall of said secondary burnchamber, wherein said secondary combustion air conduit includes a cavityspace opening to said orifices and containing baffles for diverting anddelaying airflow through said cavity space ; e) an exhaust gas manifoldcoupled to said primary burn chamber and containing said exhaust portand a baffle for directing exhaust gases to said exhaust port; f) aplurality of tubular exhaust gas conduits acutely extending between saidsecondary burn chamber and said exhaust manifold and having bores formedto produce turbulence in exhaust gases conducted therethrough; g) asource of combustion air coupled to said plurality of conduits at saidprimary burn chamber and to said secondary combustion air conduit andcontrolled to 1) direct air through the conduit orifices to positivelypressurize the primary burn chamber and direct combustion exhaust gasescontaining hydrocarbons past said secondary combustion air conduit andinto said secondary burn chamber and 2) direct preheated air from thesecondary combustion air conduit orifices to turbulently mix with thepassing exhaust gases and induce further combustion of hydrocarbons inthe exhaust gases; h) a heat exchanger having an enclosure surroundingsaid primary and secondary burn chambers, said secondary combustion airconduit, and said plurality of exhaust gas conduits and containing aliquid heat exchange media and means for circulating said liquid mediathrough said enclosure; and i) microprocessor means responsive to aplurality of inputs from temperature sensors monitoring said primary andsecondary burn chambers and exhaust gas manifold for controlling theflow of exhaust gases from said primary burn chamber, said secondaryburn chamber and exhaust gas conduits and through said exhaust gasmanifold and exhaust gas port.
 18. A boiler as set forth in claim 17including a burner coupled to said source of combustion air and fueledby a gas or liquid fuel mounted to said primary burn chamber to initiatecombustion of said biomass materials and exhaust gas hydrocarbons withinsaid primary burn chamber or independently heat the primary burnchamber.
 19. A boiler as set forth in claim 17 including a burnercoupled to said source of combustion air and fueled by a gas or liquidfuel and mounted to said secondary burn chamber to maintain secondarycombustion of exhaust gas hydrocarbons within said secondary burnchamber.